investigation of “smart parts” with embedded sensors for ... · • design and fabricate...

Yirong Lin – DOE NETL Crosscutting Project Review – Pittsburgh, PA03‐20‐2017 1/53

Investigation of “Smart Parts” with Embedded Sensors for Energy System Applications

Ahsan Choudhuri, Ph.D. Ryan Wicker, Ph.D.

Norman Love, Ph.D. Jorge Mireles, M.S.

Yirong Lin, Ph.D.

Department of Mechanical EngineeringThe University of Texas at El Paso


Agenda

Introduction and Background

Objectives

Technical Approach

Results

Summary


Motivation• Highly efficient and environmentally benign power and

fuel systems require:– Critical Sensing in modern power plants and energy systems– Higher efficiencies in energy conversion– Lower emission for near‐zero emission power plants– Enhanced material systems safety


Advanced Sensing• Harsh high temperature conditions are common to the efficient

conversion of fuels and processes for environmental control• Monitoring/estimating harsh conditions in real time is needed for high

system performance and assessing reliability

Gasifiers• Up to 1600°C• Up to 1000 PSI• Erosive, corrosive, highly reducing

Combustion Turbines• Up to 1350°C • Pressure ratios of 30:1• Thermal shock, highly oxidative• Complex geometries


• Integrated thermocouples bonded to turbine blades• Temperature measurement enabled• Signal is sensitive to harsh environments• Up to 1400 °C for short time

(J. Yang, 2012)

State‐of‐the‐Art

(X. Li, 2001)


Ultrasonic Sensor Embedding

Ultrasonic Operation


Multi‐step Fabrication

Multi‐material fabrication using EBM Fabrication of electro-mechanical system


Overview and Rationale

• “Smart parts” with embedded sensor– Built‐in monitoring capability– Accurate sensing at desired location– No change required post fabrication– Realized by 3D printing technology


Timeline


Team Description and Assignment• Ahsan Choudhuri/Norman Love

– Smart Parts testing– Smart Parts case study– High temperature assessment

• Ryan Wicker/Jorge Mireles – Smart Parts 3D printing– Sensor embedding processing

• Yirong Lin– Materials characterization– Sensing demonstration– Smart Parts testing


Scope of Work

• Design and fabricate “smart parts” with embedded sensors. – EBM 3D printing technique for fabrication of “smart parts”– Piezoceramic sensors for temperature, strain, pressure sensing.

• Evaluate the sensing capability of the “smart part” in realistic energy systems.

ip dQdt

Ap dTdt


Design of the Fabrication Process

• “Stop and Go” process, first of its kind• 3D Printing manually interrupted• Sensor embedded during fabrication at desired location


Objectives• Objective 1: Fabricate energy system related components with embedded

sensors– Fabrication & evaluation of components without sensor by EBM– Manufacturing “Smart Parts” with embedded sensor by EBM

• Objective 2: Evaluate the mechanical properties and sensing functionalities of the “smart parts” with embedded piezoceramic sensors

– Evaluation of interfacial shear properties – Characterization of the sensing capability

• Objective 3: Assess in‐situ sensing capability of energy system parts – Short & long term testing to determine sensor reliability – Cyclic and constant loading to determine the sensing repeatability and stability


Electron Beam Meltingby Oakridge National Lab


Fabrication• Powder Material: Ti‐6Al‐4V • Mask Plate and Start Plate: Stainless steel• Layer Thickness: 50 µm

Powder Material: Ti‐6Al‐4V

Mask Plate and Start Plate: Stainless steel

Layer Thickness:50µm


Insert part (Ti‐6Al‐4V)Alumina plate

Piezoceramic sensorElectrode

(Ti)

Exploded View

Bottom part (Ti‐6Al‐4V)

Sensor assembly in “Smart parts”


Characterization

Alumina Plate Piezoelectric SensorTi Electrodes

10mm 10mm 10mm

After EBM

Before EBM


Sensor Packaging Design

Insert part (Ti‐6Al‐4V)

Bottom part (Ti‐6Al‐4V)

Piezoceramicsensor

Housing

Electrode


Sensor Packaging Fabrication

MachinableAlumina

Injection Modeling 3D printing 3D printing

+Ceramic spray


Smart parts Fabrication (1st run)

Before Fabrication

Final Part

10 mm


Force Sensing


Compression Force sensing15 Hz

20 Hz 25 Hz

10 Hz


Mechanical Property Testing

2ndbuilt

10 μm1stbuilt

Control

Stop and go

110 GPa

100 GPa


Interfacial Property EnhancementExperimental Setup

Tensile bars were fabricated to test mechanical properties after interrupting the

fabrication process

Fabrication was stopped at gauge’s midpoint, the machine was allowed to fully cool and the process was restarted

Fabricated tensile bars


25

Interfacial Property EnhancementExperimental Setup


Fracture Surface

26

Single Melt Double Melt Triple Melt


Joint Microstructure

Hossain, M.S., Gonzalez, J.A., Martinez‐Hernandez, R., Shuvo, M.A., Mireles, J., Choudhuri, A., Lin, Y., Wicker, R.B., (2016). Fabrication of smart parts using powder bed fusion additive manufacturing technology. Journal of Additive Manufacturing,10, pp. 58‐66

Ti‐6Al‐4V

Ti‐6Al‐4V

Standard part fabrication

Adjacent fabrication

Interface


Smart Tube Fabrication

Assembled Bottom Section

Masking plate


Pressure Sensing

a) (b)

(c) (d)

• Force sensing with embedded sensor demonstrated

• 1,5,10 Hz of dynamic force was used

• 0.04, 0.011 and 0.0064 (V/kN) of sensitivity was achieved

• Lower sensitivity caused by sensor packaging clearance and force loading directions


Temperature Sensing

HeatedAir

Thermocouplesplacedatinletandsurface

PyroelectricCurrent

d Sensed temperatures of 198 ºC, 178 ºC, and 150 ºC for 7.6 cm, 15.2 cm and 30.5 cm long tube sections


Selective Laser Melting Demo


CAD Drawing of Smart Injector

3D View

Fuel inlet

Air inlet

Screw hole for fixture

• Thermal soak-back sensing

• Allows for operation at lower safety factors

• Higher temperatures and higher efficiencies

HeatFlux


Design of Smart Injector Fabrication

33

Fabrication of insert part

Sensor assembly

Final smart part Fabrication of entire part

Fabrication of bottom part


Fabricated Smart Injector

• The smart injector was fabricated using selective laser melting (SLM) technology

• The electrode wires are visible in the injector

• PZT and LiNbO3 sensor material is embedded inside the injector

• The injector was cut off from the build plate after finishing preliminary sensor testing

20 mm

Build plate

Electrode wires


Traditional Machining

Selective Laser Melting

(3D printing)

Electron Beam Melting

(3D printing)

Surface Roughness Comparison between SLM, EBM, and Machining

Cost:

EDM Machined: $6,000, 2 months

SLM 3D printing: $1,500, 2 days


Preliminary Temperature Sensing Setup of the 3D printed injector

ip dQdt

Ap dTdt


Pre‐test• Prove that each valve is working properly• Make sure all readings are correct from

pressure and temperature transducers and flow meters (ambient or zero)

• The line will be pressurized and Snoop will be used on each connection to check for leaks.

Measuring pressure drop across the system (Cold flow testing)• Pressure drop testing will be performed

on each line using Nitrogen. Then we will know how much pressure on the tank will be needed to satisfy the desired chamber pressure

Hot firing test• The test will begin by setting the k‐bottles

to the indicated pressure indicated in the test matrix and setting LabVIEW to the automated sequence.

In‐situ Sensing Demonstration Procedures


Smart Fuel Injector Testing Setup

Multi‐purpose Optically Accessible

Combustor (MOAC)

Bunker


• Designed primarily for LOX/Methane combustion research

• Capability to simulate up to 50 lb thrusters

• Square chamber, inner dimensions 80x80x150mm

• Wide side quartz windows for optical access and laser diagnostics

• Modular injector/converging section

• Stands 20 bar as maximum pressure

Fig 1. MOAC CAD model

Fig 2. MOAC assembly

MOAC System

Combustion Body –Air/CH4

Quartz Windows

Metal Frame

Quartz Windows

Modeling of the Surface roughness vs Pressure drop


Oxygen

Nitrogen

Methane

OB‐1

NB‐1

FB‐1

ON‐1

FN‐1

OS‐1

FS‐1

OR‐1

FR‐1

OF‐1

FF‐1

OC‐1

FC‐1

OP‐1

FP‐1

OT‐1

FT‐1

OS‐2

FS‐2

NS‐1

NC‐1

NS‐2

NC‐2

WP‐1 WT‐2WP‐2

WB‐9

WB‐10

WB‐1

WB‐2

WB‐8

WB‐3

Pump

WF‐1

WB‐7

WE‐1

Reservoir

Ball Valve

Check Valve

Drain

Filter

Flow Meter

Needle Valve

Pressure Relief Valve

Pressure Transducer

Pump

Reservoir

Solenoid Valve

Thermocouple

WB‐11

Kevlar Wall

Control Room MHD Combustor

Exhaust Ventilation System

WB‐4

WB‐5

WB‐6

WN‐1

WB‐12

Schematic and bunker diagram


Pressure drop and flow rate test of machined injector

Solenoid valve

Pressuretransducer

LabView

Solenoid valve controlFlow meter Bypass


Flow rate and pressure drop results of machined injector


Pressure drop and flow rate test of 3D printed injector


Flow rate and pressure drop results of 3D printed injector


Insertion of 3D printed injectorElectrodes


Leak test using helium

Leak


Spark electrodes fabrication and testing

4‐5 kVSpark


Torch igniter assembly

Air MethaneSparkerBending


Hot fire testing of CH4 and air using a 3D printed injector

Stoichiometric equation for combustion of CH4 and air:

CH4 + 2(O2 + 3.76N2) CO2 + 2H2O + 7.52N2

Molecular weight of CH4 = 16.043 g/molMolar mass

C = 12.011 X 1 atom X 1 moleH = 1.008 X 4 atom X 1 mole

Molecular weight of 2(O2 + 3.76N2) = 274.66 g/molMolar mass

O = 15.9994 X 2 atoms X 2 moles = 64N = 14.007 x 2 atoms x 7.52 moles = 210.66 g/mol

O/f= ..

O/f= 17.16

Stoichiometric O/F calculated and estimated chamber pressures were used in CEA to calculate the temperatures experienced in the chamber and at the throat as well as the characteristic velocity c* (cstar). cstar was used to calculate the

total flow rate exiting the chamber at the throat as follows:

∗ ∗

Once the temperature has been calculated from CEA, this can be used to describe the enthalpy change of the combustion and calculate energy, and then

finding flow rate of fuel is possible using the following equations:

or∗

Flow rates for both the air and fuel are now known and test matrix can be done using these expected flow rates and chamber pressures to begin cold test.

The time that the test would take to get to temperature desired is also calculated by the following:

∗ ∆∆

Test matrix will be followed during the cold testing. Tank pressures will be added once pressure drop is known.

Chamber Pressure Units 20 25 30 35 40 45Methane flow LPM 4.9 6.85 8.22 9.59 10.96 12.32Air flow LPM 93.26 109.63 131.54 153.45 175.36 209.6Fuel tank pressure PSIAir tank pressure PSI


Testing Setup Ready


Publication and Patent • Gonzalez, J., Mireles, J., Lin, Y., and Wicker, R., 2017,“Economical analysis of different metal 3D printing technologies,” Additive Manufacturing, in review.

• Hossain, M., Gonzalez, J., Mireles, J., Choudhuri., Lin, Y. and Wicker., R., 2017. “Interfacial tuning of Electron Beam Melting 3D printing in ‘Stop and Go’ Metal Fabrication”. Additive Manufacturing, in review.

• Martinez, R., Hossain, M., Mireles, J., Lin, Y., and Wicker, R., 2017,“Design, Fabrication, and Testing of smart tube with embedded smart materials using electron beam melting technology ,” Smart Materials and Structures, in review.

• Hossain, M., Mireles, J., Wicker, R., 2017,“Computer vision enabled ‘stop and go’ alignment process in metal 3D printing,” Computer‐aided design and manufacturing, in review.

• Gonzalez, J., Mireles, J., Lin, Y., and Wicker, R., 2016,“Characterization of ceramic components fabricated using binder jetting additive manufacturing technology,” Ceramics International, in press.

• Hossain, M., Gonzalez, J., Martinez, R., Shuvo, M., Mireles, J., Choudhuri., Wicker., and Lin, Y., 2015. “Fabrication and Characterization of Smart Parts using Electron Beam Melting Additive Manufacturing Technology”. Additive Manufacturing, in Press.

• Gaytan, S., Cadena, M., Karim, H., Delfin, D., Lin, Y., Espalin, D. MacDonald, E. and Wicker, R., 2015, “Fabrication of barium titante by binder jetting additive manufacturing technology,” Ceramics International, 41, 6610‐6619.

• M. S. Hossain, J. Mireles, and R. Wicker, “Method of Fabrication for the repair and augmentation of part functionality of metallic components”, U.S. Patent Pending, filed with U.S. Patent and Trademark Office, October 2015

• Gonzalez, J. A., Hossain, M. S., Martinez, R., Rodriguez, G., Shuvo, M.A.I., Mireles, J., Wicker, R., Choudhuri, A., Lin, Y. 2015, "Investigation on Smart Parts with Embedded Piezoelectric Sensors via Additive Manufacturing: Characterization of Smart Parts", 5th Southwest Energy Science and Engineering Symposium (SESES), April 4th, El Paso, TX.

• Hossain, M. S., Gonzalez, J. A., Mireles, J., Lin, Y., Choudhuri, A., and Wicker, R., 2015, “Smart Part Fabrication using Electron Beam Melting Additive Manufacturing Technology”, 5th Southwest Energy Science and Engineering Symposium, El Paso, TX.

• Gonzalez, Jose A., Mireles J., Lin Y., Wicker R.B., 2015, "Fabrication of Ceramic Components Using Binder Jetting Additive Manufacturing Technology." 5th Southwest Energy Science and Engineering Symposium (SESES), April 4th, El Paso, TX.

• Hossain, M. S., Gonzalez, J. A., Mireles, J., Lin, Y., Choudhuri, A., and Wicker, R., 2015, “Smart Part Fabrication using Electron Beam Melting Additive Manufacturing Technology”, 2016 Southwest Emerging Technology Symposium, El Paso, TX.

• Hossain, M. S., Gonzalez, J. A., Gaytan, S. M., Lin, Y., Choudhuri, A., and Wicker, R., “Stop and Go Process to Fabricate Smart Parts using Electron Beam Melting”, Power Industry Division Symposium, 2014.


Acknowledgment• Funding support from DOE-NETL, grant DE-FE0012321

• Maria Reidpath– Federal Project Manager, Crosscutting Research, NETL, U.S. DOE

• Robert Romanosky– Acting Technology Manager, Crosscutting Research, NETL, U.S. DOE

Intel, incNavAir Exxon Mobile Intel, inc Intel, inc

Arconic

Intel, inc


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